In the manufacturing process of aspherical and spherical optics, precise measurement of radius error, sag error, and form error are crucial. Interferometers and spherometers are utilized for accurate measurements. However, the traditional method of manually collecting and inputting measurement data to CNC machines for error compensation is time-consuming and inefficient. To tackle this issue, a closed-loop manufacturing approach is proposed to minimize defective workpieces and enhance production efficiency. The storage, collection, processing, and networking of data through a local area network (LAN) server for closed-loop error compensation can play a vital role in the manufacturing process. Furthermore, the integration of industrial robots allows uninterrupted manufacturing without the need for human operators, enabling continuous production for extended periods facilitated by automated guided robotic arms. These advancements streamline the manufacturing process, improve efficiency, reduce labor costs, and enhance the overall quality of spherical and aspherical optics production.
Quality control is a critical aspect in the manufacturing of high-quality optical components. However, the traditional metrology techniques of sag meters and test plates are often performed as the final step in the polishing process, leading to an increased number of defective parts and increased production costs caused by the need for many test plates. In this paper, we present an innovative approach to measuring the radius of curvature and form error using an interferometer. The traditional method needs a pair of test plates for each curvature radius. This could cause very high costs in storage and maintenance for long-term use. In contrast, an interferometer can measure different radii of workpieces and is highly accurate. The measured data can be used in a closed-loop feedback system to compensate for form error and radius errors in CNC-controlled polishing machines. This innovative approach will significantly improve flexibility and reduce the costs of the polishing process.
The metrology for quality control is mostly the last step in the traditional manufacturing processes. According to the measuring results, the produced parts are separated into “good” (within tolerance) and “bad” (out of tolerance) parts. The “bad” parts will be treated as a loss of production. Due to many unpredictable factors, some like tool wear, room temperature change, size variation of the row workpiece, and so on, could lead to some parts out of tolerance and many “bad” parts will be produced day by day. This paper will present an innovative method to integrate metrology in the manufacturing processes with smart control systems which could reduce the amount of “bad” parts tremendously. The metrology will be realized in-process, in-situ, or between two process steps. The measuring results will be used as feedback information to correct the command parameters for the control of the process. In such a way, the quality control of the manufacturing process will be carried out in a closed loop. The loss of production could be reduced to the minimum level.
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